TFT LCD automobile light fixture

ABSTRACT

A light bar has a circuit board positioned within a housing and having a plurality of light emitting diodes (LEDs) or a thin-film-transistor liquid-crystal display (TFT LCD) is configured to transmit light. The housing has wiring electrically connected to a controller. The controller is configured to receive signals from the electrical system of the vehicle, interpret the signals received from the electrical system of the vehicle, and in response automatically control illumination of independently controllable segments of the vehicle light bar. The controller is initially programmed to perform specific function(s) and/or strobe according to specific patterns and is thereafter at least partially restricted from being reprogrammed by a user to serve other function(s), either by restricting the emission of light in at least one color and/or preventing specific strobing pattern(s).

CROSS REFERENCE TO RELATED APPLICATIONS

This is a continuation patent application claiming priority under 35U.S.C. § 120 to U.S. Ser. No. 16/601,181, filed Oct. 14, 2019, which isa divisional patent application claiming priority to U.S. Ser. No.16/511,853, filed Jul. 15, 2019, which is a continuation-in-part patentapplication claiming priority to U.S. Ser. No. 16/176,112, filed Oct.31, 2018 and issued as U.S. Pat. No. 10,351,050 on Jul. 16, 2019. Thesepatent applications are herein incorporated by reference in theirentirety, including without limitation, the specification, claims, andabstract, as well as any figures, tables, appendices, or drawingsthereof.

FIELD OF THE INVENTION

This invention relates to lights. More specifically, and withoutlimitation, this invention relates to a light bar which is particularlywell suited for use on trucks in a low-profile manner in the space abovea bumper and below the tailgate.

BACKGROUND OF THE INVENTION

The background description provided herein gives context for the presentdisclosure. Work of the presently named inventors, as well as aspects ofthe description that may not otherwise qualify as prior art at the timeof filing, are neither expressly nor impliedly admitted as prior art.

Vehicle lights are old and well known. Countless forms of vehicle lightsexist, including: headlights, fog lights, tail lights, reverse lights,parking lights, daytime running lights, and turning lights, amongcountless others. Each type of light or light configuration serves itsown unique purpose and provides its own unique advantages.

With improvements in light technology, such as the development of lightemitting diodes (“LEDs”), a great variety of accessory lights have beendeveloped. These accessory lights come in a wide array of configurationsand provide their own unique functions and advantages.

One common form of an accessory light is known as a light bar. Lightbars are designed to fit in the small space between the upper edge ofthe bumper and the lower edge of the tailgate of a pickup truck andinclude a long array of lights that are electrically connected to theelectrical system of the vehicle. These light bars provide improvedillumination and thereby improve visibility when breaking, turning andbacking up.

While conventional light bars provide many advantages, they suffer frommany disadvantages not solved by the prior art. Namely, the lightingpatterns and capabilities of known light bars are either manually set byan operator of the vehicle or interpreted in response to signalsdirectly received from the electrical system of the vehicle, therebycontrolling illumination of the LEDs of the light bar. No known lightbars include the option to manually set a lighting pattern whilesimultaneously interpreting signals directly received from theelectrical system of the vehicle. Furthermore, there are no known lightbars which reconcile whether a manual instruction from an operator ofthe vehicle or an automatic system for interpreting signals directlyreceived from the electrical system of the vehicle should have priorityover the other during simultaneous use.

There exists a need in the art for a light bar that allows the operatorto send an input to the light bar for a specific pattern of lights whilethe light bar simultaneously interprets signals directly received fromthe electrical system. There exists a further need in the art for alight bar which does not require the user to provide the input for thespecific pattern of lights and/or restricts the user to using only anumber of predetermined patterns and/or colors. There exists an evenfurther need in the art for a light bar which harmonizes which lightsshould light up in the event these instructions conflict with oneanother.

BRIEF SUMMARY OF THE INVENTION

Therefore, it is a primary object, feature, or advantage of theinvention to improve on or overcome the deficiencies in the art.

It is still yet a further object, feature, or advantage of the inventionto provide a light bar that may be used in a wide variety ofapplications and may be implemented on and used universally with almostany vehicle, including police cars, fire trucks, security vehicles, andambulances.

It is still yet a further object, feature, or advantage of the inventionto provide a light bar having LEDs of various colors. For example, thelight bar may include white LEDs, red LEDs, amber LEDs, blue LEDs, greenLEDs, etc. The light bar may include solid or split color variations,and the color variations may be changeable by remote control.

It is still yet a further object, feature, or advantage of the inventionto provide a light bar having single stock-keeping unit (SKU) which iscapable of preforming several functions, emitting light in severaldifferent colors, and/or strobing light according to several differentpatterns; programmed for performing a specific function selected fromthe total group of capable functions, emitting light in some of theseveral different colors, and/or strobing light according to some of theseveral different patterns; and, later, restricted from preforming atleast one function, emitting light in at least one color, and/orstrobing light according to one pattern.

It is still yet a further object, feature, or advantage of the inventionto provide a light bar having a solid state design. For example, thelight bar includes more than two thousand chip-on-board LEDs, a compactsize, and a completely encapsulated interior.

It is still yet a further object, feature, or advantage of the inventionto provide a light bar having, preferably, a liquid-crystal display LCD;more preferably, a thin-film-transistor liquid-crystal display (TFTLCD); and most preferably, a TFT LCD with independently controllableportions (e.g. groups of pixels).

It is still yet a further object, feature, or advantage of the inventionto provide a semi-flexible or flexible light bar for allowinginstallation on gradually curved surfaces.

It is still yet a further object, feature, or advantage of the inventionto provide light bars of various sizes that fit in the space between thebumper and the tailgate of most trucks, mount inside the vehicle invarious window locations or outside of the vehicle at any externallocation on the vehicle and are included with tool boxes or otherobjects associated with the vehicle.

It is still yet a further object, feature, or advantage of the inventionto provide a clip for mounting the light bar to any of the locationslisted above or any other suitable location on a vehicle.

It is still yet a further object, feature, or advantage of the inventionto provide a light bar that improves the safety of drivers.

It is still yet a further object, feature, or advantage of the inventionto provide a cost effective and durable (e.g., water, weather, andcontaminant proof) light bar.

It is still yet a further object, feature, or advantage of the inventionto provide a light bar that is aesthetically pleasing.

It is still yet a further object, feature, or advantage of the inventionto practice methods which facilitate use, manufacture, transport,installation, uninstallation, repair, assembly, disassembly, storage,and the cleaning of a light bar.

It is still yet a further object, feature, or advantage of the presentinvention to incorporate an apparatus into a system accomplishing someor all of the previously stated objectives.

The previous objects, features, and/or advantages of the presentinvention, as well as the following aspects and/or embodiments, are notexhaustive and do not limit the overall disclosure. No single embodimentneed provide each and every object, feature, or advantage. Any of theobjects, features, advantages, aspects, and/or embodiments disclosedherein can be integrated with one another, either in full or in part, aswould be understood from reading the present disclosure.

According to some aspects of the present disclosure, a vehicle light barcomprises a circuit board positioned within a housing and having aplurality of light emitting diodes (LEDs) initially capable oftransmitting light in at least four different colors. The housing haswiring electrically connected to a control box. The control box includeslogic for automatically illuminating independently controllable segmentsof the vehicle light bar and a microprocessor. The microprocessor isprogrammed to control light emission according to one or more selectedstrobing patterns and restrict light emission in at least one of the atleast four different colors.

According to some additional aspects of the present disclosure, spacebetween an outward facing surface of the circuit board and an inwardfacing surface of the housing is filled with an encapsulant therebysealing the LEDs within the housing.

According to some additional aspects of the present disclosure, theencapsulant is formed of a flowable plastic injected into space betweenthe outward facing surface of the circuit board and the inward facingsurface of the housing.

According to some additional aspects of the present disclosure, aportion of the housing covering the LEDs is formed of a transparent ortranslucent plastic material.

According to some additional aspects of the present disclosure, thehousing is formed of a back wall, a pair of opposing sidewalls and acover, wherein the cover is formed of a convex curved shape.

According to some additional aspects of the present disclosure, theoutward facing surface of the circuit board is black in color therebyminimizing the noticeability of the vehicle light bar when not inoperation.

According to some additional aspects of the present disclosure, the LEDsare chip-on-board LEDs.

According to some additional aspects of the present disclosure, thewiring includes a fuse and a signal lead.

According to some additional aspects of the present disclosure, thewiring comprises gold.

According to some additional aspects of the present disclosure, thecircuit board includes four rows of LEDs, wherein at least one row isformed of red LEDs, wherein at least one row is blue LEDs, at least onerow is formed of amber LEDs, and at least one row is formed of whiteLEDs.

According to some additional aspects of the present disclosure, themicroprocessor is programmed to automatically illuminate some of the redLEDs while a vehicle is braking, illuminate some of the amber LEDs whilethe vehicle is turning, illuminate some of the white LEDs while thevehicle is driven in reverse, and is restricted from illuminating theblue LEDs.

According to some additional aspects of the present disclosure, themicroprocessor is programmed to automatically illuminate any combinationof some of the blue LEDs, red LEDs, and white LEDs during an emergencyand is restricted from illuminating the amber LEDs.

According to some additional aspects of the present disclosure, themicroprocessor is programmed to automatically illuminate any combinationof some of the blue LEDs, amber LEDs, and white LEDs during work orconstruction related tasks and is restricted from illuminating the redLEDs.

According to some other aspects of the present disclosure, a vehiclelight bar for installation on a vehicle having an electrical systemcomprises a circuit board positioned within a housing and having a thinfilm transistor liquid-crystal display (TFT LCD) and a controllerelectrically connected to the electrical system of the vehicle,electrically connected to the TFT LCD, and having a microprocessor andmemory. The controller is configured to receive signals from theelectrical system of the vehicle, interpret the signals received fromthe electrical system of the vehicle, and in response automaticallycontrol illumination of the TFT LCD. The controller includes logic forautomatically illuminating independently controllable portions of theTFT LCD and a microprocessor programmed to control light emissionaccording to one or more selected strobing patterns and restrict lightemission in at least one of the at least four different colors.

According to some additional aspects of the present disclosure, thecontroller is further configured to select between colors or strobingpatterns in response to receiving the signals from the electrical systemof the vehicle and the controller is further configured to select theduration of illumination of the TFT LCD in response to receiving thesignals from the electrical system of the vehicle.

According to some additional aspects of the present disclosure, the oneor more selected strobing patterns are emergency related and the one ormore other strobing patterns are work or construction related.

According to some additional aspects of the present disclosure, the oneor more selected strobing patterns are work or construction related andthe one or more other strobing patterns are emergency related.

According to some other aspects of the present disclosure, a method ofmanufacturing a vehicle light bar comprises positioning a circuit boardhaving a plurality of light emitting diodes (LEDs) or a thin filmtransistor liquid-crystal display (TFT LCD) within a housing,electrically connecting a controller to the plurality of LEDs or the TFTLCD, said controller having a microprocessor and memory, configuring thecontroller to receive signals from the electrical system of the vehicle,interpret the signals received from the electrical system of thevehicle, and in response automatically control illumination of theplurality of LEDs or TFT LCD, programming the microprocessor to controllight emission according to one or more selected strobing patternsand/or in one or more colors; and programming the microprocessor torestrict emission of light according to one or more other strobingpatterns and/or in one or more other colors. The controller includeslogic for automatically illuminating independently controllable segmentsof the plurality of LEDs or independently controllable portions of theTFT LCD.

According to some additional aspects of the present disclosure, themethod further comprises removing a portion of the housing to form aviewing window for the LEDs or TFT LCD.

According to some additional aspects of the present disclosure, themethod further comprises mounting the vehicle light bar onto a vehicle,a support bar attached to the vehicle, and/or an accessory of thevehicle and electrically connecting the controller to an electricalsystem of the vehicle.

These and/or other objects, features, advantages, aspects, and/orembodiments will become apparent to those skilled in the art afterreviewing the following brief and detailed descriptions of the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a clip for use with the vehicle lightbar system presented herein, the clip is configured to attach to thebody of a vehicle using adhesive and/or a fastener, the clip includes aback wall that is generally planar in shape and includes opposing armspositioned in each corner of the back wall that extend upward therefrom,the arms include a feature positioned at the outward end of opposingarms that extend toward one another, this feature is configured to griponto the light bar when the light bar is forced between the opposingarms thereby holding the light bar within the clip, the outward ends ofthe arms also include a guiding surface angles toward the open interiorof the clip that is configured to guide the light bar between opposingarms, according to some aspects of the present disclosure.

FIG. 1B is an elevation view of the clip shown in FIG. 1A, the viewtaken from the top surface of the clip, according to some aspects of thepresent disclosure.

FIG. 1C is an elevation view of the clip shown in FIGS. 1A and 1B, theview taken from the side surface of the clip, the view showing the armsextending upward a distance from the back wall, according to someaspects of the present disclosure.

FIG. 1D is an elevation view of the clip shown in FIGS. 1A, 1B, and 1C,the view taken from the end of the clip, the view showing the distancebetween opposing arms that extend upward a distance from the back wall;the view showing the feature positioned at the outward end of opposingarms that extend toward one another, this feature is configured to griponto the light bar when the light bar is forced between the opposingarms thereby holding the light bar within the clip, the view also showsthe guiding surface positioned at the outward ends of the arms thatangles toward the open interior of the clip that is configured to guidethe light bar between opposing arms, according to some aspects of thepresent disclosure.

FIG. 2 is an elevation schematic view of the light bar system, the viewshowing the light bar having three rows of LEDs, the view showing thewiring system connected to the light bar, the view showing the controlbox connected to the wiring system, the view showing the fuse and plug,and electrical leads connected to the light bar that are configured toconnect to the electrical system of the vehicle to which the light baris attached, according to some aspects of the present disclosure.

FIG. 3 is an elevation view of a side cut away of the assembled housingof the light bar, the view showing the housing having a back wall,opposing side walls and a cover with a pair of right angled steps thatserve as features positioned between the cover and the sidewalls, theview showing the circuit board formed of a backing material, circuitrylayer and LEDs positioned within the hollow interior of the housing, theview showing the ribbon wire extending below the backing material of thecircuit board, the view showing the first layer of encapsulantencapsulating the outward facing surface of the circuit board includingthe three rows of LEDs, the view also showing the second layer ofencapsulant the essentially fills all the remaining space within thehollow interior of the housing thereby fully encapsulating the circuitboard and all other components positioned within the hollow interior ofthe housing, according to some aspects of the present disclosure.

FIG. 4 is a side elevation view of a side cut away of the assembledhousing of the light bar of FIG. 3, the view showing the addition of theclip shown in FIGS. 1A-1D attached to the exterior of the housing, theview showing the features of the arms of the clip connected to andholding onto the features of the housing positioned between thesidewalls of the housing and the cover of the housing, the view showingthe interior surface of the sidewalls of the arms in approximately flatand flush engagement with the exterior surface of the sidewalls of thehousing, the view showing the exterior surface of the back wall of thehousing in approximately flat and flush engagement with the forwardsurface of the back wall of the clip, according to some aspects of thepresent disclosure.

FIG. 5 is a perspective view of the clip of FIGS. 1A-1D shown in a sideby side position to a portion of the housing of the light bar, accordingto some aspects of the present disclosure.

FIG. 6 is a perspective view of the clip of FIGS. 1A-1D shown partiallyinstalled on a portion of the housing of the light bar, the view showingone end of the light bar installed on the clip and one end of the lightbar not installed on the clip, according to some aspects of the presentdisclosure.

FIG. 7 is a perspective view similar to FIG. 6 with the portion of thehousing fully installed within the clip, according to some aspects ofthe present disclosure.

FIG. 8 is a perspective view of the fully assembled light bar, the viewshowing three rows of LEDs visible through the transparent portion ofthe housing, a row of red LEDs, a row of white LEDs and a row of amberLEDs, according to some aspects of the present disclosure.

FIGS. 9A-G show detailed electrical schematic views of the light barsystem of FIG. 2, the views showing the exemplary electrical componentsand logic used for automatically overriding the continuousinterpretation of signals directly received from the electrical systemof the vehicle with a manual instruction and resulting pattern caused byilluminating the LEDs at specific times, according to some aspects ofthe present disclosure.

FIG. 10 shows an elevation view of a wireless remote capable of sendinga manual instruction or signal which corresponds with a specificlighting pattern for the light bar shown in FIG. 2, according to someaspects of the present disclosure.

FIG. 11 shows exemplary vehicles which may have use for an emergencylight bar, including a police car, a security vehicle, a fire truck, andan ambulance, according to some aspects of the present disclosure.

FIG. 12 shows possible color combinations and strobing patternsassociated with an emergency light bar, according to some aspects of thepresent disclosure.

FIG. 13 shows exemplary vehicles which may have use for an emergencylight bar, including a pickup truck and a construction vehicle includinga boom, according to some aspects of the present disclosure.

FIG. 14 shows possible color combinations and strobing patternsassociated with a work light bar, according to some aspects of thepresent disclosure.

FIG. 15 shows a vehicle light bar system incorporating athin-film-transistor liquid-crystal display (TFT LCD), according to someaspects of the present disclosure.

FIG. 16 shows an end perspective view of vehicle light bar systemattached to a support bar which can mount to an automobile, according tosome aspects of the present disclosure.

FIG. 17 shows an opposite end perspective view of vehicle light barsystem attached to a support bar which can mount to an automobile,according to some aspects of the present disclosure.

FIG. 18 shows a diagram illustrating an exemplary hardware environmentfor practicing the present invention, according to some aspects of thepresent disclosure.

Several embodiments in which the present invention may be practiced areillustrated and described in detail, wherein like reference numeralsrepresent like components throughout the several views. The drawings arepresented for exemplary purposes and may not be to scale, unlessotherwise indicated, and thus proportions of features in the drawingsshall not be construed as evidence of actual proportions.

DETAILED DESCRIPTION Definitions—Introductory Matters

The following definitions and introductory matters are provided tofacilitate an understanding of the present invention. Unless definedotherwise, all technical and scientific terms used herein have the samemeaning as commonly understood by one of ordinary skill in the art towhich embodiments of the present invention pertain.

The terms “a,” “an,” and “the” include singular and plural referents.

The term “or” is synonymous with “and/or” and means any one member orcombination of members of a particular list.

The terms “invention” or “present invention” as used herein are notintended to refer to any single embodiment of the particular inventionbut encompass all possible embodiments as described in the specificationand the claims.

The term “about” as used herein refers to slight variations in numericalquantities with respect to any quantifiable variable. One of ordinaryskill in the art will recognize inadvertent error can occur, forexample, through use of typical measuring techniques or equipment orfrom differences in the manufacture, source, or purity of components.The claims include equivalents to the quantities whether or not modifiedby the term “about.”

The term “configured” describes an apparatus, system, or other structurethat is constructed to perform or capable of performing a particulartask or to adopt a particular configuration. The term “configured” canbe used interchangeably with other similar phrases such as constructed,arranged, adapted, manufactured, and the like.

Numerical adjectives and adverbs (e.g., first, second, etc.), positionaladjectives and adverbs (e.g., vertical, horizontal, forward, aft, etc.),and nouns describing orientation of an object (e.g., top, bottom, sides,etc.), are referenced according to the views presented. Unless contextindicates otherwise, these terms are not limiting. The physicalconfiguration of an object or a combination of objects may changewithout departing from the scope of the present invention.

The light bar described herein is described, as one example, for usewith a pickup truck. This is by way of example only, and any use ishereby contemplated and reference to use on a pickup truck is not to belimiting. Instead, the light bar presented herein is contemplated foruse in any application and may be used on any vehicle. In addition, theshape and dimensions of the light bar can be modified without departingfrom the spirit and scope of the invention.

In communications and computing, a computer readable medium is a mediumcapable of storing data in a format readable by a mechanical device. Theterm “non-transitory” is used herein to refer to computer readable media(CRM) that store data for short periods or in the presence of power suchas a memory device or random-access memory (RAM).

A processing unit, also called a processor, is an electronic circuitwhich performs operations on some external data source, usually memoryor some other data stream. Non-limiting examples of processors include amicroprocessor, a microcontroller, an arithmetic logic unit (“ALU”), andmost notably, a central processing unit (“CPU”). A CPU, also called acentral processor or main processor, is the electronic circuitry withina computer that carries out the instructions of a computer program byperforming the basic arithmetic, logic, controlling, and input/output(“I/O”) operations specified by the instructions.

One or more embodiments described herein can be implemented usingprogrammatic modules, engines, or components. A programmatic module,engine, or component can include a program, a sub-routine, a portion ofa program, or a software component or a hardware component capable ofperforming one or more stated tasks or functions. A module or componentcan exist on a hardware component independently of other modules orcomponents. Alternatively, a module or component can be a shared elementor process of other modules, programs, or machines.

As would be apparent to one of ordinary skill in the art, mechanical,procedural, or other changes may be made without departing from thespirit and scope of the invention. The scope of the invention is definedonly by the appended claims, along with the full scope of equivalents towhich such claims are entitled.

Overview

System:

With reference to the figures, light bar system 10 is presented (alsoreferred to herein as light bar 10 and/or system 10). The system 10includes the component pieces of housing 12, circuit board 14 which isseparated into segments 16, end caps 18, encapsulant 20, control box 22having a microprocessor 24 and memory 26, among other components as isdescribed herein. The system 10 also includes one or more clips 28 thatfacilitate connection of the light bar 10 to a truck or vehicle 30, anaccessory mounted to the truck or vehicle 30, and/or a support bar 130mountable to the truck or vehicle 30 (such as the one shown in FIGS. 16and 17 or the “vehicle accessory bar” disclosed in U.S. patentapplication Ser. No. 15/964,311, which is commonly owned and hereinincorporated by reference in its entirety).

Housing:

Housing 12 is formed of any suitable size, shape and design and isconfigured to house the electrical components of the light bar system10. In one arrangement, as is shown, housing 12 is an elongated hollowmember that extends a length between opposing ends that are closed byend caps 18. Housing 12 includes a back wall 32 that is generally flatand planar in shape when viewed from the side. The upper and lower edgesof back wall 32 that extend the length of housing 12 connect to opposingsidewalls 34. Like back wall 32, sidewalls 34 are generally flat andplanar in shape. Opposing sidewalls 34 connect at their rearward edgesto the upper and lower edges of back wall 32 and extend in approximateparallel spaced alignment to one another. Sidewalls 34 extend inapproximate perpendicular alignment to back wall 32. This arrangement,with the generally planar and perpendicular alignment of the back wall32 and side walls 34 form a generally rectangular space between the backwall 32 and opposing side walls 34, as can be seen from the side cutaway view of FIGS. 3 and 4.

The forward edges of sidewalls 34 connect to a cover portion 36 ofhousing 12. In the arrangement shown, cover portion 36 has a generallysmooth and curved exterior surface that connects at its upper and loweredges to the forward edges of sidewalls 34. In the arrangement shown,cover portion 36 has a convex exterior surface, and a concave interiorsurface, that helps to shed water, dirt and contaminants off of thehousing. However, any other size, shape and design is contemplated foruse as cover portion 36, including a flat and square shape, a peakedshape, a concave shape or any other shape.

In one arrangement, as is shown, one or more features 38 are positionedat the intersection or connection point between sidewalls 34 and coverportion 36. Features 38 are formed of any suitable size, shape anddesign and are configured to support the engagement between andconnection of clip 28 to housing 12 and to facilitate a strong anddurable hold there between while also facilitating selective removal ofhousing 12 from clip 28. As one example, as is shown, features 38include a first step or ledge positioned between the exterior surface ofsidewalls 34 and where cover portion 36 connects to sidewalls 34. Inthis arrangement, the first step of features 38 include a smallgenerally planar portion that extends in approximate parallel spacedrelation to back wall 32 which serves as a connection point for clip 28to hold on to and secure housing 12. That is, in the arrangement shown,the first step of features 38 is a small generally right angle notch orstep between sidewall 34 and cover portion 36 when viewed from the sideas can be seen in FIGS. 3 and 4. Also, in the arrangement shown, asecond step is also positioned just above the first step of features 38and is configured in a similar manner. That is, in the arrangementshown, the second step of features 38 is a small generally right anglenotch or step between sidewall 34 and cover portion 36 that connects atits lower or outward side to the first step of features and connects atits upper or outward side to cover portion 38 when viewed from the sideas can be seen in FIGS. 3 and 4. In the arrangement wherein more thanone step is present in features 38, clip 28 may connect to only one ofthe steps or both of the steps. Any number of steps is herebycontemplated for use as features 38 such as none, one, two, three, fouror more. Alternatively, any other size, shape and design for features 38is hereby contemplated for use, such as a hook, a concave recess that isrecessed inward toward back wall 32, a protrusion or any other shapedfeature 38, which in some configurations or applications may provide amore-affirmative and durable connection between clip 28 and housing 12.

The connection of back wall 32, sidewalls 34 and cover portion 36 definea hollow interior 40 there between which houses and holds circuit board14 therein. In one arrangement, housing 12 is formed of a singlemonolithic piece or extrusion and therefore the features, size and shapeof housing 12 extend the length of housing 12. Being formed of a singlepiece reduces the number of parts, simplifies the manufacturing processin many ways (and complicates it in other ways) and provides enhancedwater proofing and contaminant protection as there are no seams orconnection points for infiltration of water or contaminants into thehollow interior 30 of housing 12. As such, the hollow interior 40 ofhousing 12 serves as a complete or as close to a complete shield towater and contaminants as is possible. This arrangement providesenhanced the water and contaminant protection for the componentspositioned within the hollow interior 40 of housing 12. To providefurther protection, the components positioned within the hollow interior40 of housing 12 are encapsulated in an encapsulant 20 as is furtherdescribed herein. Having a consistent size and shape throughout thelength of housing 12 facilitates easier installation as clip 28 can bepositioned along any portion of housing 12 and the components can beinserted into hollow interior 40 of housing 12 from either end and thesecomponents may be slid along the length of hollow interior 40 of housing12 during installation.

In the arrangement shown, housing 12 includes a transparent portion 42and a non-transparent portion 44. In one arrangement, the back wall 32and the sidewalls 34 or only the rearward portions of sidewalls 34 ofhousing 12 are painted with a black or dark or non-transparent paintwhich is placed on the exterior and/or the interior of housing 12.Alternatively these portions of housing 12 (back wall 32 and all or aportion of sidewalls 34) are formed of a black or dark ornon-transparent material that prevents or reduces light transmissionthere through. In this arrangement, the cover portion 36 and the forwardportions of sidewalls 34 of housing 12 are formed of a clear,transparent, translucent or other material that allows light to betransmitted there through. In one arrangement, the color black has beentested with success as it reduces the appearance of the system 10 wheninstalled on vehicle 30. In the arrangement where the back wall 32 andsidewalls 34 and the cover portion 36 are formed of different coloredmaterials, the back wall 32 and sidewalls 34 are manufactured as asingle unitary piece of two different colored materials or two materialswith different colors and light-transmission properties, such as aco-extrusion process or the like so as to form a single unitary andsimultaneously manufactured piece without seams or other areas wherewater or contaminants can infiltrate the housing 12.

In an alternative arrangement, housing 12 is formed multiple pieces. Inone arrangement, a back portion or non-transparent portion 44, connectsto a front portion or transparent portion 42 along a connection point orseamline that is glued, welded, adhered or connected in any other way toone another. In this arrangement, the back portion or non-transparentportion 44 is formed of a black or dark or non-transparent material oris painted with a black or dark or non-transparent paint, whereas thefront portion or transparent portion 42 is formed of a transparent ortranslucent material that allows light to be transmitted there through.In one arrangement, the back portion or non-transparent portion 44 isformed of the back wall 32 and the entirety of the sidewalls 34 whichconnect to the cover portion 36 at the outward ends of sidewalls 34. Inanother arrangement, the back portion or non-transparent portion 44 isformed of the back wall 32 and a portion of the sidewalls 34 whichconnect to the cover portion 36 which includes a portion of thesidewalls 34 and as such, sidewalls 34 connect to one another along aseamline where the back portion of the sidewalls 34 are part of thenontransparent portion 44 and the forward portion of the sidewalls 34are part of the transparent portion 42. Any other configuration ishereby contemplated for use.

Circuit Board:

Circuit board 14 is formed of any suitable size, shape and design and isconfigured to house a plurality of light emitting diodes 46 (“LEDs”)thereon and facilitate selective illumination of the LEDs 46. In onearrangement, as is shown, circuit board 14 is formed of a backingmaterial 48 and a circuitry layer 50.

Backing material 48 is formed of any suitable size, shape and design andserves to provide support to circuitry layer 50 as well as serve heatdissipation purposes. In one arrangement, backing material 48 is formedof a metallic material, such as aluminum, copper, an aluminum alloy, acopper alloy, or any other metallic material, rigid material and/ormaterial the provides for support and/or heat dissipation. In analternative arrangement backing material 48 is formed of a non-metallicmaterial.

Backing material 48 provides structural support for circuitry layer 50as well as heat dissipation. That is, when circuitry layer 50 isconnected to backing material 48 and backing material 48 is formed of amaterial with a high coefficient of diffusivity (such as aluminum, analuminum alloy, copper, a copper alloy, or another alloy material)backing material 48 helps to absorb and diffuse heat generated by LEDs46. To maximize space utilization within the hollow interior 40 ofhousing 12, backing material 48 is relatively thick, and substantiallythicker than circuitry layer 50, and backing material 48 fits within thehollow interior 40 of housing 12 within relatively close and tighttolerances. In the arrangement shown, when viewed from the side, backingmaterial 48 is generally rectangular in shape with an opposing back walland forward wall that approximate the size of or are slightly the sizeof the interior surface of back wall 32 of housing 12 and are positionedin approximate parallel planar spaced relationship with one another; andsimilarly backing material 48 has a pair of opposing sidewalls thatextend a portion of the interior surface of sidewalls 34. The width ofbacking material 48 is slightly smaller than the width between theinterior surfaces of opposing sidewalls 34 of housing 12 so as tofacilitate insertion of backing material 48 into the hollow interior 40of housing 12. The height of backing material 48 is smaller than theheight of the interior surfaces of sidewalls 34 so as to provide roomfor ribbon wire 63 behind backing material 48 as well as to provide roomfor circuitry layer 50 and LEDs 46 on top of backing material 48.Maximizing the size of backing material 48 within the hollow interior 40of housing 12, while providing ample room for the other components ofthe system 10 maximizes heat diffusion and structural rigidity providedby backing material 48.

Circuitry layer 50 is formed of any suitable size shape and design andprovides the electrical connection between the electrical components ofthe system 10. In one arrangement, circuitry layer 50 includes theelectrical leads and traces that connect and interconnect the electricalcomponents of system 10 including LEDs 46, ribbon wire 63 and controlbox 22. Circuitry layer 50 may be formed of multiple layers itself so asto provide electrical isolation between the many electrical leadstherein.

While backing material 48 and circuitry layer 50 are described asseparate components in one arrangement they may be formed as a singlecomponent, or alternatively they may be formed of separate components.That is, circuitry layer 50 may be manufactured separately and thenapplied to backing material 48. Alternatively, circuitry layer 50 may beformed onto and/or into backing material 48.

Circuit board 14 is formed of any suitable size shape and design and isconfigured to house, hold and provide the electrical connections forLEDs 46. In the arrangement shown, circuit board 14 includes three rowsof densely packed LEDs 46 that extend a length or the entire lengthbetween end caps 18 within the hollow interior 40 of housing 12,including a row of amber LEDs 46A, a row of white LEDs 46W and a row ofred LEDs 46R. In the arrangement shown, the white LEDs 46 are positionedin the middle with the red and amber LEDs 46 positioned on oppositesides of the row of white LEDs 46, however any other configuration ishereby contemplated for use.

To provide independent control of various portions of light bar system10, circuit board 14 is electrically separated into a plurality ofsegments 16. Segments 16 allow for independent control of each segment.In the arrangement shown, light bar 10 is separated approximately downits middle at a seamline 54 into two separate segments 16, such as adriver's side segment 16 and a passenger side segment 16. Segments 16can be independently illuminated as well as simultaneously illuminated.Separating light bar 10 into driver side and passenger side segments 16allows the control box 22 to illuminate the entire length of light bar10 for breaking and backing up, as well as illuminating only one segment16 for the turning signal. While only two segments 16 are shown, anynumber of segments 16 are hereby contemplated for use.

To reduce the appearance of the light bar 10 when installed, theexterior facing surface 55 of circuit board 14 is a dark or black color.This dark or black color reduces the visibility of the light bar 10 wheninstalled thereby improving the aesthetic appearance of the light bar10.

Endcaps & Wiring:

End caps 18 are formed of any suitable size, shape and design and serveto close the hollow interior 40 of housing 12 at its outward ends. Inone arrangement, one end cap 18 allows the passage of wiring 56 therethrough whereas the opposite end cap 18 does not have wiring 56 passingthere through and as such this end cap 18 simply closes the opposite endof housing 12 from the wiring end cap 18. To continue with thelow-profile appearance theme of the light bar 10, in one arrangement,end caps 18 are formed of a black material, like the back portion ornon-transparent portion 44 of housing 12. End caps 18 are friction fitas well as sealed within the hollow interior 40 of housing 12 so as toprevent water and contaminants from entering hollow interior 40. Endcaps 18 are sealed into housing 12 by any manner, method or means suchas gluing, adhering, welding, heat shrinking, taping, wrapping and/orany combination thereof or the like.

Wiring 56 is made up of an electrically conductive material such as ametal or alloy. Non-limiting examples of electrically conductivematerials include, gold, gold alloys, copper, copper alloys, silver,silver alloys, nickel, nickel alloys, palladium, palladium alloys, zinc,and zinc alloys may be used. In at least one embodiment, the use of agold alloy for wiring 56 is preferred.

Wiring 56 exiting one end of housing 12 electrically connects to controlbox 22 and includes a fuse 58 before electrically connecting to a plug60. Plug 60 is formed of any suitable size, shape and design and in onearrangement is formed of a conventional four-way trailer plug thatelectrically connects to the electrical system of many standard vehicles30. However any other form of plug is hereby contemplated for use as isdirectly wiring the wiring 56 of light bar 10 into the wiring system ofvehicle 30.

In one arrangement, wiring 56 also includes one or more signal leads 62.Signal lead 62 is an electrical lead that is configured to beelectrically connected to electrical system of vehicle 30, and morespecifically a reverse light lead, a left turn signal lead, a right turnsignal lead or another electrical lead of vehicle 30. In combination,plug 60 and signal lead(s) 62 are configured to receive power andoperational signals from vehicle 30 and provide operational signals tolight bar 10. That is, as a user operates vehicle 30, the lights in theback of the vehicle 30, where light bar 10 is positioned, are controlledin various ways. That is, when the user presses the brake pedal, thebrake lights of the light bar 10 illuminate until the brake pedal isreleased; when the user engages a turn signal, the appropriate turnsignal of the light bar 10 periodically flashes until the turn signal isdisengaged; when the user places the vehicle 30 in reverse, the reverselights of the light bar 10 illuminate until the vehicle 30 is removedfrom reverse; when the user turns the hazard lights on, the brake lightsof the light bar 10 flash until the hazard lights are turned off, and soon. Signal lead 62, as well as the other wires of wiring 56, areconfigured to receive and transmit the operational signals to the lightbar 10 so that light bar 10 can illuminate appropriately and incoordination with the lights of vehicle 30.

In the arrangement wherein the light bar 10 is formed of two segments16, a ribbon wire 63 extends outward from an end of each segment 16.That is, a ribbon wire 63 connects to the first segment 16 and extendsoutward through the end cap 18 that allows passage of the ribbon wire 63there through. A second ribbon wire 63 extends under the circuit board14 of the first and second segment 16 and electrically connects to theend of second segment 16 opposite first segment 16. This ribbon wire 63also extends out the same end cap 18 such that both wires extend out ofthe same end of housing 12. In the arrangement shown, ribbon wire 63includes six wires, or three pairs of wires, one pair for each color ofLED 46 (white LED 46W, red LED 46R, and amber LED 46A). As depth of thesystem 10 is important to maintain the low profile nature of the system10, to minimize the depth of the system, only two segments 16 are usedand therefore only one layer of ribbon wire 63 extends below thesegments 16. Having the ribbon wire 63 extend out of the outward ends ofthe segments 16 allows the circuit boards 14 and backing material 48 andcircuitry layer 50 connect to one another in flush alignment with oneanother at seamline 54 in flush and flat engagement with little to nogap there between. This allows for practically seamless illuminationbetween opposing segments 16 and makes it practically impossible todistinguish between the opposing segments 16 as the spacing of the LEDs46 is maintained across the seamline 54. That is, the seamline 16 doesnot disturb the continuous spacing of LEDs 46 from one segment 16 to theother segment 16. In fact, the seamline 54 is itself hard to see whenlight bar 10 is inspected.

Control Box:

System 10 includes a control box 22. Control box 22 is formed of anysuitable size, shape and design and is configured to receive operationalsignals from the electrical system of vehicle 30, interpret thesesignals and output operational signals that control operation of lightbar 10. Control box 22 includes a microprocessor 64 and memory 66 amongother components. Microprocessor 64 is any device which receivesinformational signals, interprets these signals, and outputs informationor commands based on instructions stored in memory 66. Memory 66 is anyform of an informational storage device or system, such as RAM, flashmemory, a hard drive, or the like. Information or instructions in theform of software, code, firmware or the like are stored on memory 66 andis accessible to microprocessor 64. Microprocessor 64 and memory 66 maybe formed of a single unitary device, separate but electricallyconnected devices, or a plurality of separate but electrically connecteddevices.

The microprocessor 64 is programmed to instruct light emitting devices,such as LEDs 46, to emit light according to one or more selectedstrobing patterns. The microprocessor can be further configured torestrict the emission of light in at least one of the at least fourdifferent colors such that the manufacturer can limit the capability ofthe light bar 10 before sale to a consumer. This means that only asingle stock-keeping unit (SKU) is necessary to create light bars whichare capable of performing any specific function, and other functions notuseful to the ordinary consumer (e.g. police emergency light features)are prevented either by restricting the emission of light in at leastone color and/or preventing specific strobing patterns. This programmingprocess is in explained in more detail below, under the section heading“Programming of the Microcontroller.”

Since light bar 10 is configured to be installed on practically anyvehicle 30, microprocessor 64 and memory 66 are programmed to interpretsignals from multiple types of vehicles and output the appropriateoperational signals. That is, in one arrangement, microprocessor 64 andmemory 66 are programmed to detect or determine what type of vehiclethey are connected to and then determine the appropriate operationalsignal to output based on what operational signals are received asinput. In this way, the use of control box 22 and microprocessor 64 andmemory 66 allows for seamless utilization of a single light bar 10 formultiple makes and models of vehicle 30 without the need to program orreprogram the microprocessor 64 and memory 66 for each vehicle 30. Thisincreases the speed and ease of installation and use.

The microprocessor 64 shown in FIG. 9E may also be programmed tooverride the automatic interpretation of signals and illumination of theindependently controllable segments of the vehicle light bar in theevent a manual instruction is sent by an operator with a strobingpattern. The microprocessor 64 for example may be a PIC16F676. In someembodiments, the microprocessor 64 may be a 14 pin, flash-based 8-bitCMOS microcontroller and may include a high-performance reducedinstruction set computer (RISC) CPU. The RISC CPU has only 35instructions to learn, all of which are single-cycle except branches; anoperating speed associated with a 20 MHz oscillator/clock input and a200 ns instruction cycle; an interrupt capability; an 8-level deephardware stack; a direct, indirect, and relative addressing modes. Themicroprocessor 64 features internal and external oscillator options,with a precision internal 4 MHz oscillator factory calibrated to +/−1%,an external oscillator support for crystals and resonators, and a 5 μswake-up from sleep, 3.0V, typical; a power-saving sleep mode; a wideoperating voltage range −2.0V to 5.5V; an industrial and extendedtemperature range; a low-power power-on reset (POR); a power-up timer(PWRT) and oscillator start-up timer (OST); a brown-out detect (BOD); awatchdog timer (WDT) with independent oscillator for reliable operation;a multiplexed MCLR/input-pin; an interrupt-on-pin change; an individualprogrammable weak pull-ups; and a programmable code protection; a highendurance flash/EEPROM cell with a 100,000 write flash endurance, a1,000,000 write EEPROM endurance, and a flash/data EEPROM retentiongreater than 40 years. The microprocessor 64 may have several low-powerfeatures including a standby current of 1 nA at 2.0V, typical; anoperating current of 8.5 μA at 32 kHz, 2.0V, typical or 100 μA at 1 mHz,2.0V, typical; a watchdog timer current of 300 nA at 2.0V, typical; anda timer 1 oscillator current of 4 μA at 32 kHz, 2.0V, typical. Themicroprocessor 64 may also peripherally feature 12 I/O pins withindividual direction control, high current sink/source for direct LEDdrive, an analog comparator module with one analog comparator, aprogrammable on-chip comparator voltage reference (CV_(REF)) module, aprogrammable input multiplexing from device inputs, and a comparatoroutput that is externally accessible; an analog-to-digital convertermodule with a 10-bit resolution, a programmable 8-channel input, and avoltage reference input; an enhanced timer with a 16-bit timer/counterwith a prescaler, an external gate input mode, and an option to use OSC1and OSC2 in LP mode as a timer oscillator, if INTOSC mode is selected;and in-circuit serial programming via two pins.

The strobing pattern may be selected from the group consisting of anemergency strobing pattern and a work light strobing pattern, as shownin FIGS. 12 and 14. The strobing patterns may be employed on light bars10 utilized with the exemplary vehicles shown in FIGS. 10 and 11.

For an emergency light bar, the light bar 10 may be segmented into twoindependently controllable light segments that have red, white, and blueLEDs. The light bar 10 may achieve any of the possible colorcombinations shown in FIG. 12. For example, the left independentlycontrollable light bar segment may be red and the right independentlycontrollable light bar segment may be blue, the left independentlycontrollable light bar segment may be white and the right independentlycontrollable light bar segment may be off, or any other combination ofred, blue, white, and off.

For a work or construction light bar, the light bar 10 may be segmentedinto two independently controllable light segments that have amber,white, and blue LEDs. The light be 10 may achieve any of the possiblecolor combinations shown in FIG. 14. For example, the left independentlycontrollable light bar segment may be amber and the right independentlycontrollable light bar segment may be blue, the left independentlycontrollable light bar segment may be white and the right independentlycontrollable light bar segment may be off, or any other combination ofamber, blue, white, and off.

Other color combinations and purposes for using the light bar 10 notexpressly disclosed herein are still contemplated by the presentinvention. Other examples of non-limiting colors of LEDs could includegreen, purple, yellow, silver, etc. and other non-limiting examples ofpurposes could include customizing the look of vehicles, administeringfunerals, etc.

The lights in FIGS. 11-14 may strobe by turning off for one pulse andthen turning back on; by pulsing in triplets; or by an operator manuallypulsing the lights, potentially via the use of a remote control, such asthe remote control 70 in FIG. 10. Such a remote control may be wirelessand may allow an operator to manually choose the timing, color, andbrightness of a pulse by sending an instruction to the microprocessor 64to perform a specific strobing pattern. The manual instruction may alsobe created by switches, buttons, or dials that are directly oroperationally attached to the control box 22. Still in otherembodiments, the manual instruction could be controlled by depressingthe pedals, using turn signals, etc. In other words, the manualinstruction could be used to override the normal operational lights ofthe vehicle or the normal operational lights of the vehicle couldoverride a specific strobing pattern, such as an emergency or work lightstrobing pattern. The different pulsing and color combinations result inat least sixty-four separate strobe operations in addition to acompletely white override and the ability to manually pulse the lights.

Electrical Components of the Control Box and the Circuit Board:

As shown in FIGS. 9A-9C, the portion of the circuit board 14 and controlbox 22 associated with each individual LED 46 (e.g., a white LED in FIG.9A, a right amber LED in FIG. 9B, and a left amber LED in FIG. 9C)include any necessary logic and electrical components for automaticallyreceiving signals from the electrical system of the vehicle,interpreting the signals received from the electrical system of thevehicle, and in response automatically controlling illumination ofindependently controllable segments of the vehicle light bar.

For example, the electrical components and logic within the system maybe provided and preferably arranged according to the views presented.The system uses several resistors to reduce current flow, adjust signallevels, to divide voltages, bias active elements, and terminatetransmission lines, among other things; several capacitors to storeenergy, to smooth the output of the power supply, and for blockingdirect current while allowing alternating current to pass; severalinductors for block alternating current while allowing direct current topass and for separating signals of different frequencies; and severaldiodes for allowing an electric current to pass in one direction and toconvert alternating current to direct current.

Of particular importance in FIGS. 9A-9C is the placement of the LEDs 46and the high-efficiency step-down controller 68. The high-efficiencystep-down controller 68 is designed to operate in continuous conductionmode and drive single or multiple series connected LEDs 46 efficientlyfrom a voltage source higher than the total LED chain voltage. Forexample, the high-efficiency step-down controller 68 may be a PT4121 mayprovide an externally adjustable output current. In some embodiments,the high-efficiency step-down controller 68 includes a high-side outputcurrent sense circuit, which uses an external resistor to set thenominal average output current, and a dedicated DIM input accepts eithera DC voltage or PWM dimming. The high-efficiency step-down controller 68features a simple low parts count, a high efficiency up to 97%, singlepin on/off and brightness control using DC voltage or PWM, up to 1 MHzswitching frequency, adjustable constant LED current, typical 3% outputcurrent accuracy, a high-side current sense, a hysteretic control, aninherent R_(CS) open protection, an inherent open-circuit LEDprotection, an inherent short-circuit LED protection, and a thermalshutdown. The high-efficiency step-down controller 68 may be used in lowvoltage halogen replacement LEDs, automotive or decorative lighting, lowvoltage industrial lighting, as LED backup lighting, as signs/emergencylighting, etc. The recommended operating range for the high-efficiencystep-down controller 68 includes temperatures ranging from negativeforty degrees Celsius to eighty-five degrees Celsius and a supply wideinput voltage from 6V to 60V. Exceeding these ranges may damage thedevice or cause the device to cease functioning. When the deviceoperates at high ambient temperature, or when driving maximum loadcurrent, care must be taken to avoid exceeding the package powerdissipation limits.

In some embodiments, the high-efficiency step-down controller 68, inconjunction with a current sense resistor (R_(CS)), an inductor (L₁),and a MOSFET, forms a self-oscillating continuous-mode buck converter.When the input voltage (VIN) is first applied, the initial current inthe inductor and the current sense resistor is zero and there is nooutput from the current sense circuit. Under this condition, the outputof a current sensing comparator is high. This turns on switch, causingcurrent to flow from the input voltage to ground, via the current senseresistor, the LEDs 46, the inductor, and the external MOSFET. Thecurrent rises at a rate determined by the input voltage and the inductorto produce a voltage ramp (VSCN) across the current sense resistor. Whenthe difference between the input voltage and the voltage ramp is greaterthan 230 mV, the output of the current sensing comparator switches lowand the switch turns off. The current flowing on the current senseresistor decreases at another rate. When the difference between theinput voltage and the voltage ramp is less than 170 mV, the switch turnson again and the mean current on the LED 46 is determined by 200 mV pereach current sense resistor. The high-side current-sensing scheme andon-board current-setting circuitry minimize the number of externalcomponents while delivering LED current with ±3% accuracy, using a 1%sense resistor. The high-efficiency step-down controller 68 allowsdimming with a PWM signal at the DIM input. A logic level below 0.3V atDIM forces the high-efficiency step-down controller 68 to turn off theLED 46 and the logic level at DIM must be at least 2.5V to turn on thefull LED current. The frequency of PWM dimming ranges from 100 Hz to 20kHz. The DIM pin can be driven by an external DC voltage (V_(DIM)) toadjust the output current to a value below the nominal average valuedefined by the current sense resistor. The DC voltage is valid from 0.5Vto 2.5V. When the DC voltage is higher than 2.5V, the output currentkeeps constant. Additionally, to ensure the reliability, thehigh-efficiency step-down controller 68 is built with a thermal shutdown(TSD) protection. The thermal shutdown protects the integrated circuitfrom over temperature (above one hundred-fifty degrees Celsius).

As shown in FIGS. 9A-9C, the high-efficiency step-down controller 68 asshown includes the following pins: 1 VIN, an input power supply pinconnected to a decoupling capacitor from VIN pin the ground; 2 CSN, anLED current sense input connected to a current-sense resistor thatprograms LED average current to the VIN pin; 3 DIM, a logic leveldimming input driving the DIM pin low to turn off the current regulatorand driving the DIM pin high to enable the current regulator; 4 GND, thesignal and power ground connected directly to a ground plane; 5 DRV, agate-driver output connected to the gate of the external MOSFET; and 6VCC, an internal regulator output connected to a 1 μF decoupling capfrom the VCC pin to the ground. In still other embodiments (not shown),the high-efficiency step-down controller 68 may include two or more pinsthat are not initially connected to anything for further versatility.

The nominal average output current in the LEDs 46 is determined by thevalue of the external current sense resistor connected between VIN andCSN and is given by I_(OUT)/R_(CS). This equation is valid when DIM pinis float or applied with a voltage higher than 2.5V (must be less than5V). Actually, the current sense resistor sets the maximum averagecurrent which can be adjusted to a less one by dimming.

The DIM pin can be driven by an external DC voltage (V_(DIM)), to adjustthe output current to a value below the nominal average value defined bythe current sense resistor. The average output current is given by

$I_{OUT} = {\frac{0.2 \times V_{DIM}}{2.5 \times R_{CS}}{\left( {0.5 \leq V_{DIM} \leq {2.5V}} \right).\mspace{14mu} 100}\%}$brightness corresponds to 2.5V≤V_(DIM)≤5V.

A pulse with modulated (PWM) signal with duty cycle PWM can be appliedto the DIM pin, to adjust the output current to a value below thenominal average value set by the current sense resistor. PWM dimmingprovides reduced brightness by modulating the LEDs 46 forward currentbetween 0% and 100%. The LED brightness is controlled by adjusting therelative ratios of the on time to the off time. A 25% brightness levelis achieved by turning the LED on at full current for 25% of one cycle.To ensure this switching process between on and off state is invisibleby human eyes, the switching frequency must be greater than 100 Hz, thehuman eyes average the on and off times, seeing only an effectivebrightness that is proportional to the LEDs on-time duty cycle. Theadvantage PWM dimming is that the forward current is always constant,therefore the LED color does not vary with brightness as it does withanalog dimming. Pulsing the current provides precise brightness controlwhile preserving the color purity the dimming frequency of thehigh-efficiency step-down controller 68 can be as high as 20 kHz.

An external capacitor from the DIM pin to ground will provide additionalsoft-start delay, by increasing the time taken or the voltage on thispin to rise to the turn-on threshold and by slowing down the rate ofrise of the control voltage at the input of the comparator.

A low equivalent series resistance (ESR) capacitor should be used forinput decoupling, as the ESR of this capacitor appears in series withthe supply source impedance and lowers overall efficiency. Thiscapacitor has to supply the relatively high peak current to the coil andsmooth the current ripple on the input supply. A minimum value of 10 μFis acceptable if the DC input source is close to the device, but highervalues will improve performance at lower input voltages, especially whenthe source impedance is high. The voltage rating should be greater thanthe input voltage. The input capacitor should be placed as close aspossible to the integrated circuit. For maximum stability overtemperature and voltage, capacitors with X7R, X5R, or better dielectricare recommended. Capacitors with &5V dielectric are not suitable fordecoupling in this application and should not be used.

Lower value of inductance can result in a higher switching frequency,which causes a larger switching loss. Choose a switch frequency between100 kHz to 500 kHz for most applications. According to switchingfrequency, inductor value can be estimated as:

$L = \frac{\left( {1 - \frac{V_{OUT}}{V_{IN}}} \right) \times V_{OUT}}{0.3 \times I_{LED} \times {fsw}}$For higher efficiency, choose an inductor with a DC resistance as smallas possible.

For most applications, the output capacitor is not necessary. Peak topeak ripple current in the LEDs 46 can be reduced below 30% of theaverage current, if required, by adding a capacitor across the LEDs 46.A value of 2.2 μF will meet most requirements. Proportionally lowerripple can be achieved with higher capacitor values. Note that thecapacitor will not affect operating frequency or efficiency, but it willincrease start-up delay and reduce the frequency of dimming, by reducingthe rate of rise of LED voltage.

The current sense resistor should be placed close to the VIN pin and CSNpin in order to minimize current sense error. The input loop includinginput capacitor, Schottky diode, and MOSFET which should be as short aspossible.

Clip:

Clip 28 is formed of any suitable size, shape and design and isconfigured to connect housing 12 to vehicle 30. In one arrangement, asis shown, clip 28 has a back wall 100 that extends between opposing endwalls 102 and opposing sidewalls 104. Back wall 100 has a generally flatforward face 106 and a generally flat rearward face 108 that form planesthat extend in approximate parallel spaced relation to one another.Opposing sidewalls 104 extend in approximate parallel spaced relation toone another and opposing end walls 102 extend in approximate parallelspaced relation to one another. As such, sidewalls 104 and end walls 102extend in approximate perpendicular alignment to one another therebyforming a generally rectangular member.

A pair of opposing arms 110 are connected to each end of clip 28. Arms110 are connected to sidewalls 104 and extend upward a distance fromforward face 106. The outward edge of arm 110 is in planar alignmentwith sidewall 104. The outward end of arm 110 is in alignment with endwall 102 and extends inward a distance therefrom. Arms 110 include alocking feature 112 positioned at their outward most end. Lockingfeatures 112 are formed of any suitable size, shape and design and aredesigned to engage and lock housing 12 into clip 28. In one arrangement,locking features 112 are formed of a step or ledge or hook that matinglyengage the feature 38 or step in the exterior surface of housing 12positioned at the intersection of cover portion 36 and sidewalls 34. Inthe arrangement shown, when clip 28 is viewed from the and end 102,locking features 112 on opposing arms 110 extend inward and over theforward face of back wall 100 a distance. Accordingly, to facilitatelocking engagement, arms 110 extend upward from forward face 106approximately the same distance as sidewall 34 of housing 12.

To further facilitate a firm, durable and strong connection between clip28 and housing 12, arms 110 are slightly biased inward toward oneanother. This causes the distance between the outward ends of arms 110to be slightly narrower than the width of housing 12. As such, whenhousing 12 is placed between opposing arms 110 and locked into place aninward force is applied on housing 12 by arms 110. This helps to holdhousing 12 within clip 28. This also helps to keep engagement betweenlocking feature 112 of arm 110 and the feature 38 of housing 12.

Due to the slight inward bias of the arms 110 of clip 28, the outwardmost ends of arms 110 include a curved or angled guiding surface 114.Guiding surface 114 helps to guide the housing 12 into the space betweenopposing arms 110. In the arrangement shown, guiding surface 114 curvesor angles inward from the upper most end of arms 110 down to the step oflocking feature 112. This causes the upper ends of guiding surface 114to be wider than the width of back wall 32 of housing 12, while thelower end of guiding surface 114 is narrower than the width of back wall32 of housing 12. This causes the arms 110 to flex or bend outward asthe light bar 10 is forced within the clip 28.

The rearward face 108 of back wall 100 is flat and thereby providesmaximum surface area for connection to the body of vehicle 30. Thisallows for the use of an adhesive, such as a double sided tape or foamor gel to be positioned between the rearward face 108 of clip 28 and thebody of vehicle 30. Using adhesive eliminates the need to put screws orbolts into the body of vehicle 30, simplifies the installation process,speeds the installation process, eliminates the need to use tools toinstall the clips 28 and provides a durable installation.

Despite that the installation process that uses adhesives instead ofdrilling and screwing, back wall 100 includes an opening 116 thereinthat facilitates reception of a screw or other fastening device thereinif the installer chooses to use a fastener. In one arrangement, toensure the head of the screw does not protrude, the opening 116 iscountersunk. That is, the walls of the opening angle inward as theyextend from forward face 106 to rearward face 108.

Installation and Use:

The system 10 is installed by first placing adhesive on the rearwardface 108 of a plurality of clips 28. In one arrangement, the clips 28are then adhered to the body of vehicle 30. Once the clips 28 areinstalled on the vehicle 30, the housing 12 is aligned with the clips 28and the housing 12 is forced into the clips 28. Alternatively, the clips28 are installed onto the housing 12 and then the housing 12 and clips28 are simultaneously installed onto the body of the vehicle 30.

When the housing 12 is forced into the clips 28, the back wall 32 ofhousing 12 engages the upper or outward end of the guiding surface 114of arms 110 of clips 28. As the guiding surfaces 114 angle inward andbecause the arms 110 are angled slightly inward, force is appliedcausing the arms 110 to elastically bend outward as the housing 12 isforced downward between opposing arms 110. The arms 110 continue to bendoutward until the ledge or step of features 112 of clip 28 passes orengages the step or features 38 of housing 12. At this point the lockingfeatures 112 of arms 110 engage or lock onto the step or features 38 ofhousing 12 thereby locking the housing 12 within the clip 28 with astrong and durable connection. In this position, the flat back wall 32of housing 12 is in flat and flush engagement with the forward face 106of the flat back wall 100 of clip 28. In this position, the exteriorsurface of sidewalls 34 of housing 12 are in flat and flush engagementwith the interior faces of arms 110 of clip 28. In this position, thelower surface of features 112 in the end of arms 110 are in flat andflush locking engagement with the upper surface of the features 38 ofthe housing 12.

Once the housing 12 is installed, the plug 60 and signal lead 62 areconnected to the electrical system of the vehicle 30, as shown in FIGS.2 and 9D-E. Once electrically connected, the control box 22 andmicroprocessor 64 and memory 66 receive power and operational signalsfrom the electrical system of the vehicle 30. Power may be deliveredfrom the electrical system via the power supply shown in FIG. 9F. Themicroprocessor 64 interprets these signals according to the instructionsstored in memory 66 and outputs operational signals that controloperation of the light bar 10.

Dimensions:

In one arrangement, to ensure that the system 10 fits practically everycommercially available pickup truck, the light bar system 10 comes intwo lengths, 60 inches or 48 inches. The use of these two lengthsfacilitates use on practically all commercially available pickup trucks.Any other length is hereby contemplated for use. The light bar has adepth approximately ⅜ of an inch without the clip 28 and approximately ½of an inch with the clip 28 installed. The light bar 10 has a height ofapproximately ⅝ of an inch without the clip 28 and ¾ of an inch with theclip 28 installed. In one arrangement, the clips 28 are approximately 3and ¼ inches long. Any other depth and/or width is hereby contemplatedfor use.

Method of Manufacture:

In one arrangement, the system 10 is manufactured in the followingmanner.

The housing 12 is extruded of a clear plastic material and the back wall32 and the rear portions of the sidewalls 34 (nontransparent portion 44)are painted with a dark or black color. Alternatively, the housing 12 isextruded and the nontransparent portion 44 is extruded of anontransparent material whereas the transparent portion 42 is extrudedof a transparent material.

Next, the circuit board 14 is formed in segments 16. This isaccomplished by installing the LEDs 46 onto the circuitry layer 50 andthen installing the LEDs 46 and circuitry layer 50 on the backingmaterial 48. Once the LEDs 46 are installed onto the circuit board 14 afirst layer 120 of encapsulant 20 is laid over the LEDs 46 and theexterior facing surface 55 of circuit board 14.

Encapsulant 20 is formed of any flowable material that seals the LEDs 46and circuit board 14. In one arrangement, encapsulant 20 is a flowablematerial when initially applied that later cures to a non-flowablematerial. In one arrangement, encapsulant 20 is a flowable plasticmaterial that is transparent or translucent. In one arrangement, whilethe encapsulant 20 is initially flowable, it hardens to a rigid,semi-rigid, flexible or rubber-like material.

Next, the separate segments 16 are connected together by aligning theadjacent segments 16 in end-to-end engagement thereby forming seamline54 there between and then an adhesive is laid over the rearward face ofthe circuit board 14, such as a glue, paste, tape, double sided tape orthe like. This using an adhesive such as a double sided tape, gel or thelike holds the two segments 16 together while also provides for adhesionof ribbon wire 63 to the back of circuit board 14 as well.

Since both segments 16 have ribbon wire 63 extending outward from an endof the segment 16, and it is desirable to have wires only coming out oneend of the housing 12, the ribbon wire 63 of one segment 16 is foldedaround and onto the back of circuit board 14 such that both ribbon wires63 extend out of the same end of system 10. In this position, theadhesive holds the folded ribbon wire 63 in place on the back of circuitboard 14.

Now that both ribbon wires 63 extend outward from the same end ofcircuit board 14, the combined and assembled circuit board 14 formed ofboth segments 16 is slid into the hollow interior 40 of housing 12through an open end of the housing 12 until the assembled circuit board14 is fully installed within the hollow interior 40 of housing 12.

Once fully installed, an end cap 18 is positioned over each end. Onceinstalled, the end caps 18 are sealed in place.

Next, to fully encapsulate the housing 12, the housing 12 is verticallyaligned, so as to help the bubbles flow out of the hollow interior 40 ofthe housing 12 and a second layer 122 of encapsulant 20 is injectedthrough the lower end cap 18 and into the remaining air-space within thehollow interior 40 of housing 12. This encapsulant 20 fills most if notall of the voids and spaces within the hollow interior 40 therebyproviding an additional contaminant and water proofing barrier. In onearrangement, this second layer 122 of encapsulant 20 is over-flowed,that is more encapsulant 20 is forced into the hollow interior 40 of thehousing 12 such that the excess escapes out the opposite end of thehousing 12 and in doing so, excess air bubbles are forced out of thehollow interior 40. The encapsulant 20 is left to cure over time. Oncecured the light bar 10 is ready for use.

When encapsulant 20 is properly injected within the hollow interior 40of housing 12, the second layer 122 of encapsulant 20 fills all of theair space left within the hollow interior 40 of housing 12. In onearrangement, the second layer 122 surrounds all portions of the circuitboard 14 and engages the entire exterior surface of the circuit board 14as well as engages the entire interior surface of the hollow interior 40of housing 12. By filling all of the air space within the hollowinterior 40 of housing 12 after the circuit board 14 has been insertedwithin the hollow interior 40 this prevents any water or contaminationfrom getting into the hollow interior 40 by filling this space already.In addition, even if water or contaminants did get into the hollowinterior 40 of housing 12 this water and/or contaminants would not beable to get to the circuit board 14 itself as the circuit board 14 isfully encapsulated within the second layer 122 of encapsulant 20. Inaddition, the LEDs 46 are also encapsulated by the first layer 120 orencapsulant 20 thereby providing a second layer of protection. Thisthese first and second layers 120, 122 of encapsulant 20 are protectedby being housed within the sealed housing 12 thereby protecting theencapsulant 20 from exposure to water and contaminants not to mentionphysical contact and abuse. By forming the housing 12 out of a singlecontinuous extrusion, this prevents water or contaminants from gettinginto housing 12 except for the ends which are covered by end caps 18that are sealed in place and then sealed again with second layer 122 ofencapsulant 20. In way, a light bar system 10 is provided that isextremely durable and practically impenetrable.

Chip-On-Board LEDs:

In one arrangement, LEDs 46 are what are known as Chip-On-Board (COB)LEDs. COB LED technology describes the mounting of a bare LED chip indirect contact with the substrate to produce LED arrays. It is a methodof LED packaging which has a number of advantages over traditionalsurface mount technologies such as the use of “T-pack” and Surface mountLEDs.

Due to the small size of the LED chip, Chip-on-Board technology allowsfor a much higher packing density than surface mount technology. Thisresults in higher intensity & greater uniformity of light for the user.

COB light source can save about 30% cost in the application, mainly liein LED package cost, light engine production costs and the secondarylight distribution costs, which is of great significance for manyapplications. In performance, through the rational design and micro-lensmolding, a COB light module can avoid the defects of point and glarelight and other deficiencies of prior art LEDs. COB modules make theproduction of lighting simpler and more-convenient, and reduce costseffectively. In production, existing technology and equipment cansupport high yield and large-scale COB module manufacturing, assemblyand installation. As such, the use of COB LEDs provides many advantagesincluding brighter illumination and an appearance of a single continuouslight instead of a plurality of individual lights.

Control Box Algorithm and Operation:

One problem associated with adding a light bar 10 having red, white andamber LEDs 46 is that a break light signal and a turn signal from thevehicle's electrical system is indistinguishable, but it is desirablefor the light bar 10 to illuminate the amber LEDs 46A on the appropriatesegment 16 of the light bar 10 for a turn signal while it is desirableto illuminate the red LEDs 46R of both segments 16 for a break light. Inaddition, to provide the maximum visibility and safety, it is desirableto illuminate both the red LEDs 46R of a segment 16 and the amber LEDs46A when the breaks are applied while the turn signal is on. Yet, again,in many applications, the break and turning signals areindistinguishable from one another as they merely appear as power to aline through plug 60.

To accomplish this functionality, and separate the turn signals frombreak signals, microprocessor 64 and memory 66 of control box 22 use analgorithm that is capable of determining whether a signal is a breaksignal or a turn signal and from this determination the control box 22illuminates the appropriate segment(s) 16 of light bar 10 and theappropriate color(s) of LEDs 46.

More specifically, in one arrangement, control box 22 receives power andfour electrical operational signals from the electrical system of thevehicle 30. These four operational signals are: (1) a tail light signal(which is a low power signal on both the right tail light lead and theleft tail light lead), (2) a reverse light signal, (3) a leftblinker/brake signal, and (4) a right blinker/brake signal.

The reverse signal is simply a pass through signal. That is, when thereverse signal is received, the white LEDs 46W of both segments 16 areilluminated. Similarly, the tail light signal (meaning that the taillights of the vehicle are to be illuminated at a low level, such as whenthe headlights are on) is also a pass through signal. That is, when thetail light signal is received, the red LEDs 46R of both segments 16 areilluminated, at a low illumination level. As such, there is essentiallyno need to perform processing on the reverse light signal and/or thetail light signal.

However, processing is required to determine whether a signal is a turnsignal or a break signal. The algorithm processes three functions passedalong in two wires; left turn signal which is represented as a blinkingsignal on the left signal lead; right turn signal which is representedas a blinking signal on a right signal lead; and brake signal which isrepresented as a solid or continuous signal simultaneously present onboth the left and right signal leads. The right and left turn signalsare mutually exclusive, but the brake signal can be present at any timefor any duration.

The software algorithm uses memory of the current state and the recentpast state of the right signal lead and the left signal lead todetermine what function is most likely active at a point in time. Thatis whether it is a break signal or a turn signal. The algorithm observesthe rate at which a turn signal is flashing to estimate when the nextsignal should arrive, and the algorithm acts accordingly if that signaleither does or does not arrive. The software contains a state machine totake care of most situations, and also employs timers to keep certainstates from running too long.

In addition, the algorithm adapts to the speed of the turn signal foreach vehicle, so that if a nondeterministic state is incorrectlydetermined, the function only lasts the minimum time necessary. Thisreduces the time that an erroneous output is displayed (an output thatmay not be in sync with the vehicle). A brake released at just the righttime may activate an errant turn signal, e.g., flash of the amber LEDs46A of a segment 16. This functionality adds to the universal nature ofthe light bar.

As such, the control box 22 extrapolates these four electricaloperational signals from the electrical system of vehicle 30 into thefollowing functions using an algorithm:

-   -   Break Light: The control box 22 detects a simultaneous solid        high-intensity illumination on both the right signal lead and        the left signal lead. The control box 22 outputs a high        intensity illumination on both segments 16 of red LEDs 46R.    -   Breaks Applied and Right Turn Signal Active: The control box 22        detects a constant signal on left turn signal lead and        intermittent signal on the right turn signal lead. The control        box 22 outputs a high intensity illumination on both segments 16        of red LEDs 46R while simultaneously outputting a flashing        illumination of the amber LEDs 46A on the right segment 16 of        light bar 10.    -   Breaks Applied and Left Turn Signal Active: The control box 22        detects a constant signal on right turn signal lead and        intermittent signal on the left turn signal lead. The control        box 22 outputs a high intensity illumination on both segments 16        of red LEDs 46R while simultaneously outputting a flashing        illumination of the amber LEDs 46A on the left segment 16 of        light bar 10.    -   No Break Applied and Right Turn Signal Active: The control box        22 does not detect a signal on the left turn signal lead while        detecting an intermittent signal on the right turn signal lead.        The control box 22 outputs a flashing illumination of the amber        LEDs 46A on the right segment 16 of light bar 10.    -   No Break Applied and Left Turn Signal Active: The control box 22        does not detect a signal on the right turn signal lead while        detecting an intermittent signal on the left turn signal lead.        The control box 22 outputs a flashing illumination of the amber        LEDs 46A on the left segment 16 of light bar 10.    -   Hazards: Detecting hazards is equivalent to detecting a break        light signal. That is, the control box 22 detects a simultaneous        solid high-intensity illumination on both the right signal lead        and the left signal lead. The control box 22 outputs a high        intensity illumination on both segments 16 of red LEDs 46R. In        one arrangement, a timer function is used to detect the periodic        illumination on both the right signal lead and the left signal        lead and microprocessor 64 determines that this continued        cycling of this signal is indeed a hazard signal and the        microprocessor 64 instead illuminates that amber LEDs 46A until        the periodic cycling ceases.

Thin-Film-Transistor Liquid-Crystal Display:

As shown in FIG. 15, the light bar 10 employs a thin-film-transistorliquid-crystal display (TFT LCD) 124 in lieu of using LEDs 46. The TFTLCD 124 is a variant of a liquid-crystal display (LCD) that usesthin-film-transistor (TFT) technology to improve image qualities such asaddressability and contrast. The TFT LCD 124 is an active matrix LCD, incontrast to passive matrix LCDs or simple, direct-driven LCDs with a fewsegments. In this way, the TFT LCD can be electrically separated intomuch smaller independently controllable portions or segments that emitlight in response to control signals from the microprocessor 64.

In one embodiment, the relatively inexpensive twisted nematic (TN)display type can be used for the TFT LCD 124. The pixel response time onmodern TN panels is sufficiently fast to avoid the shadow-trail andghosting artifacts of earlier production. The more recent use of RTC(Response Time Compensation/Overdrive) technologies has allowedmanufacturers to significantly reduce grey-to-grey (G2G) transitions,without significantly increasing the ISO response time. Response timesare now quoted in G2G figures, with 4 ms and 2 ms now being commonplacefor TN-based models. TN displays can suffer from limited viewing angles,especially in the vertical direction. Colors will shift when viewedoff-perpendicular. In the vertical direction, colors will shift so muchthat they will invert past a certain angle.

In yet another embodiment, the in-plane switching (IPS) display type canbe used for the TFT LCD 124 to improve on the poor viewing angle and thepoor color reproduction of TN panels at that time. The IPS name comesfrom the main difference from TN panels: the crystal molecules moveparallel to the panel plane instead of perpendicular to it. This changereduces the amount of light scattering in the matrix, which gives IPSits characteristic wide viewing angles and good color reproduction.Initial iterations of IPS technology were initially characterized byslow response time and a low contrast ratio but later revisions havemade marked improvements to these shortcomings.

In yet another embodiment, the advanced fringe field switching (AFFS)display type can be used for the TFT LCD 124. AFFS is a technologysimilar to IPS or Super-IPS offering superior performance and colorgamut with high luminosity. Color shift and deviation caused by lightleakage is corrected by optimizing the white gamut, which also enhanceswhite/grey reproduction.

In yet another embodiment, the plane line switching (PLS) display typecan be used for the TFT LCD 124. The PLS display type bears similaritiesto IPS panels and touts improved viewing angles and image quality,increased brightness and lower production costs.

In yet another embodiment, the multi-domain vertical alignment (MVA)display type can be used for the TFT LCD 124. MVA achieves a fast pixelresponse, wide viewing angles, and high contrast at the cost ofbrightness and color reproduction. Modern MVA panels can offer wideviewing angles (second only to S-IPS technology), good black depth, goodcolor reproduction and depth, and fast response times due to the use ofresponse time compensation (RTC) technologies. When MVA panels areviewed off-perpendicular, colors will shift, but much less than for TNpanels. The pixel response times of MVAs rise dramatically with smallchanges in brightness. Less expensive MVA panels can use dithering andframe rate control (FRC).

In yet another embodiment, the patterned vertical alignment (PVA)display type can be used for the TFT LCD 124. Less expensive PVA panelsoften use dithering and FRC, whereas super-PVA (S-PVA) panels all use atleast 8 bits per color component and do not use color simulationmethods. S-PVA also largely eliminated off-angle glowing of solid blacksand reduced the off-angle gamma shift.

In yet another embodiment, the advanced super view (ASV), also calledaxially symmetric vertical alignment, display type can be used for theTFT LCD 124. ASV is a VA mode where liquid crystal molecules orientperpendicular to the substrates in the off state. The bottom sub-pixelhas continuously covered electrodes, while the upper one has a smallerarea electrode in the center of the subpixel. When the field is on, theliquid crystal molecules start to tilt towards the center of thesub-pixels because of the electric field; as a result, a continuouspinwheel alignment (CPA) is formed; the azimuthal angle rotates 360degrees continuously resulting in an excellent viewing angle. The ASVmode is also called CPA mode.

The TFT LCD 124 can be secured within the housing through first andsecond TFT LCD clips 128A, 128B. The first clip 128A can be asubstantially rectangular clip have having sidewalls adjoined by a backwall. The second clip 128B can be similarly constructed yet can alsohave a tapered section towards an external portion of the clip. Tomitigate poor viewing angles, a slight or significant portion of thehousing 12 of the light bar can be removed to create a viewing window126. Doing so helps focus light towards a location which can be easilyseen by other drivers on a road and/or other viewers of automobileimplementing the light bar system 10 described herein.

In use, the TFT LCD 124 is electrically connected to a controller and/orthe electrical system of a vehicle 30. The TFT LCD 124 can feature oneor more analog VGA, DVI, HDMI, or DisplayPort interface, with manyfeaturing a selection of these interfaces. Inside external displaydevices there can be a controller board that will convert the videosignal using color mapping and image scaling usually employing thediscrete cosine transform (DCT) in order to convert any video sourcelike CVBS, VGA, DVI, HDMI, etc. into digital RGB at the nativeresolution of the display panel. In a laptop the graphics chip willdirectly produce a signal suitable for connection to the built-in TFTdisplay. A control mechanism for the backlight is usually included onthe same controller board.

The low-level interface of STN, DSTN, or TFT display panels use eithersingle ended TTL 5 V signal for older displays or TTL 3.3 V for slightlynewer displays that transmits the pixel clock, horizontal sync, verticalsync, digital red, digital green, digital blue in parallel. Some models(for example the AT070TN92) also feature input/display enable,horizontal scan direction and vertical scan direction signals.

Because the TFT LCD 124 of the present disclosure will almost always begreater than 15 inches long, the TFT LCD 124 will often use low voltagedifferential signaling (LVDS) that transmits the same contents as theparallel interface (Hsync, Vsync, RGB) but will put control and RGB bitsinto a number of serial transmission lines synchronized to a clock whoserate is equal to the pixel rate. LVDS can transmit seven bits per clockper data line, with six bits being data and one bit used to signal ifthe other six bits need to be inverted in order to maintain DC balance.The TFT LCD 124 will, preferably, have three data lines and thereforeonly directly support 18 bits per pixel; and more preferably, have afourth data line so they can support 24 bits per pixel, which deliverstruecolor; and most preferably, have even more colors by adding a fifthlane to support 30 bits per pixel. According to another aspect of thepresent invention, LVDS with Internal DisplayPort and EmbeddedDisplayPort can be used, which allows sixfold reduction of the number ofdifferential pairs.

Backlight intensity is usually controlled by varying a few volts DC, orgenerating a PWM signal, or adjusting a potentiometer or simply fixed.This in turn controls a high-voltage (1.3 kV) DC-AC inverter or a matrixof LEDs. The method to control the intensity of LEDs is to pulse themwith PWM which can be source of harmonic flicker.

The bare display panel will only accept a digital video signal at theresolution determined by the panel pixel matrix designed at manufacture.Some screen panels will ignore the LSB bits of the color information topresent a consistent interface.

With analogue signals like VGA, the display controller also needs toperform a high-speed analog to digital conversion. With digital inputsignals like DVI or HDMI some simple reordering of the bits is neededbefore feeding it to the rescaler if the input resolution doesn't matchthe display panel resolution.

The LCDs used in calculators and other devices with similarly simpledisplays have direct-driven image elements, and therefore a voltage canbe easily applied across just one segment of these types of displayswithout interfering with the other segments. This can be impractical forthe light bar system 10 of the present disclosure because the displaywould have a large number of (color) picture elements (pixels). Thus,potentially millions of connections would be required, both top andbottom for each one of the three colors (red, green and blue) of everypixel. To avoid this issue, the pixels of the TFT LCD 124 are addressedin rows and columns, reducing the connection count from millions down tothousands. The column and row wires attach to transistor switches, onefor each pixel. The one-way current passing characteristic of thetransistor prevents the charge that is being applied to each pixel frombeing drained between refreshes to the display's image. Each pixel is asmall capacitor with a layer of insulating liquid crystal sandwichedbetween transparent conductive ITO layers.

The circuit layout process of the TFT LCD 124 is very similar to that ofsemiconductor products. However, rather than fabricating the transistorsfrom silicon, that is formed into a crystalline silicon wafer, the TFTLCD 124 is made from a thin film of amorphous silicon that is depositedon a glass panel. The silicon layer for the TFT LCD 124 is typicallydeposited using the PECVD process. Transistors take up only a smallfraction of the area of each pixel and the rest of the silicon film isetched away to allow light to easily pass through it. A polycrystallinesilicon and/or amorphous silicon-based TFT can be used to increase TFTperformance.

Programming of the Microcontroller:

The microprocessor 64 can be initially programmed to perform specificfunction(s) and/or strobe according to specific patterns and isthereafter at least partially restricted from being reprogrammed by auser to serve other function(s), either by restricting the emission oflight in at least one color and/or preventing specific strobingpattern(s). The restriction can be caused by mechanical changes to thehardware, a control module that prevent lights of a certain color frombeing emitted, or by a software application which is compatible with themicroprocessor 64.

A non-transitory computer readable medium may act as the primary meansfor programming which functions are capable of being carried out by thelight bar 10. The non-transitory computer readable medium may beoperated by person(s) considered to be the initial programmer, such as amanufacturer, which is generally a person other than the end user. Thenon-transitory computer readable medium can be a standalone device orcan form part of a phone, gaming console, tablet, other computing device(e.g. laptop and desktop computers), or even a software applicationusable with a computing device such as a web browser. The programmer isthe one who sets which functions the microprocessor 64 allows orrestricts the light bar 10 to perform.

For example, as shown in FIG. 18, an exemplary non-transitory computerreadable medium 72 that could be used to implement selected elements ofthe present invention includes a central processing unit 74 operativelyconnected to a memory 76.

The central processing unit 74 may include components such as anintelligent control and communication components (e.g., communicationsmodule 88). The central processing unit processes inputs and outputs andis capable of interfacing with many different types of modules 82, 84,86 and a user interface 90. Examples of a central processing unitinclude a processor, a microprocessor, a microcontroller, an arithmeticlogic unit (“ALU”), or any other suitable programmable device. Thecentral processing unit 74 could even include other components and canbe implemented partially or entirely on a semiconductor (e.g., afield-programmable gate array (“FPGA”)) chip, such as a chip developedthrough a register transfer level (“RTL”) design process.

The memory 76 includes, in some embodiments, a program storage area anda data storage area. The program storage area and the data storage areacan include combinations of different types of memory, such as read-onlymemory (“ROM”, an example of non-volatile memory, meaning it does notlose data when it is not connected to a power source) or random accessmemory (“RAM”, an example of volatile memory, meaning it will lose itsdata when not connected to a power source). Some additional examples ofvolatile memory include static RAM (“SRAM”), dynamic RAM (“DRAM”),synchronous DRAM (“SDRAM”), etc. Additional examples of non-volatilememory include electrically erasable programmable read only memory(“EEPROM”), flash memory, a hard disk, an SD card, etc. The centralprocessing unit 74 executes software instructions that are capable ofbeing stored in the memory 76.

Generally, the non-transitory computer readable medium 72 operates undercontrol of an operating system 78 stored in the memory 76. Thenon-transitory computer readable medium 72 implements a compiler 80which allows a software application written in a programming languagesuch as COBOL, C++, FORTRAN, or any other known programming language tobe translated into code readable by the central processing unit 74.After completion, the software application accesses and manipulates datastored in the memory 76 of the non-transitory computer readable medium72 using the relationships and logic that was generated using thecompiler 80.

In one embodiment, instructions implementing the operating system 78, asoftware application, and the compiler 80 are tangibly embodied in thenon-transitory computer readable medium 72, which could include one ormore fixed or removable data storage devices, such as a zip drive,floppy disc drive, hard drive, CD-ROM drive, tape drive, etc.

Furthermore, the operating system 78 and the software application arecomprised of instructions which, when read and executed by thenon-transitory computer readable medium 72, causes the non-transitorycomputer readable medium 72 to perform the steps necessary to implementand/or use the present invention (e.g. give or restrict functionality tothe light bar 10).

A software application and/or operating instructions may also betangibly embodied in the memory 76 and/or a communications module 88,thereby making the software application a product or article ofmanufacture according to the present invention.

For example, in a preferred embodiment, the program storage area and/ordata storage areas comprise a drive module 82, a work module 84, and anemergency module 86. The modules give the programmer the ability toquickly and turn on and off certain functionalities from the light bar10. To the end user of the light bar 10, these changes would appearpermanent.

For example, the drive module 82, would disable at least the bluecolored LEDs from emitting light. The drive module 82 can bespecifically designed to replicate or enhance traditional lightingpatterns for driving. More particularly, the drive module 82 would tellthe microcontroller to feature a white reverse light, amber turnsignals, a red running light, a red brake light, and red hazards. In yetanother embodiment, the amber turn signals could be substituted forwhite or red colored turn signals to reduce the available colors fromthree to two.

The work module 84 can be specifically designed to replicate or enhancetraditional lighting patterns for work vehicles. More particularly, thework module 84 would tell the microcontroller 64 to feature an amberstrobe, a blue strobe, a white strobe, and any combination thereof.

The emergency module 86 can be specifically designed to replicate orenhance traditional lighting patterns for emergency vehicles, such aspolice cars and ambulances. More particularly, the emergency module 84would tell the microcontroller 64 to feature a red strobe, a bluestrobe, a white strobe, and any combination thereof.

It should be appreciated that each module 82, 84, 86 can also includesubmodules which program the microcontroller 64 to emit any one or moreof the colors of lights according to specific strobing patterns inaccordance with what has been described in the Control Box section ofthe present disclosure, at specific times, for specific durations, oreven at specific speeds (or frequencies).

Furthermore, the programming of any one or more of these modules mayinclude a priority, where the lighting patterns and/or strobesassociated therewith will either override or be disabled in the eventcertain driving functions are occurring (e.g., braking, turning, etc.).If two light bars 10 are used on a single vehicle, one could beprogrammed such that lighting patterns associated with normal drivingoperations override the other available strobing patterns programmed tobe carried out by the light bar 10 and the other could be programmedsuch that the other available strobing patterns programmed to be carriedout by the light bar 10 override the lighting patterns associated withnormal driving operations. The communications module 88 can comprisedata communication devices to allow the non-transitory computer readablemedium 72 to connect to a network. The network, for example, may also beconnected to the Internet, the light bar 10, other electronic devices,and/or an electronic database.

In some embodiments, the network is, by way of example only, a wide areanetwork (“WAN”) such as a TCP/IP based network or a cellular network, alocal area network (“LAN”), a neighborhood area network (“NAN”), a homearea network (“HAN”), or a personal area network (“PAN”) employing anyof a variety of communications protocols, such as Wi-Fi, Bluetooth,ZigBee, near field communication (“NFC”), etc., although other types ofnetworks are possible and are contemplated herein. The network typicallyallows communication between the communications module 88 and a centrallocation during moments of low-quality connections. Communicationsthrough the network can be protected using one or more encryptiontechniques, such as those techniques provided in the IEEE 802.1 standardfor port-based network security, pre-shared key, ExtensibleAuthentication Protocol (“EAP”), Wired Equivalent Privacy (“WEP”),Temporal Key Integrity Protocol (“TKIP”), Wi-Fi Protected Access(“WPA”), and the like.

In some embodiments, the non-transitory computer readable medium 72could include one or more communications ports such as Ethernet, serialadvanced technology attachment (“SATA”), universal serial bus (“USB”),or integrated drive electronics (“IDE”), for transferring, receiving, orstoring data.

The non-transitory computer readable medium 72 interfaces with theprogrammer to accept input(s) and commands through at least part of theuser interface 90. Although the user interface 90 is depicted acollection of input receiving components, the instructions performingthe user interface functions can be resident or distributed in theoperating system 78, another software application, or module.Alternatively, the instructions can be implemented with special purposememory and processors.

The user interface 90 is how the programmer interacts with thenon-transitory computer readable medium 72. The user interface 90 couldbe a digital interface, a command-line interface, a graphical userinterface (“GUI”) 96, or any other way a user can interact with amachine. For example, in a preferred embodiment, the user interface 90comprises speakers 92, a display 94, and one or more means for receivingan input 98 from the programmer. The speakers 92 can transmit audio inresponse to instructions received from the operating system 78, thenon-transitory computer readable medium 72, the drive module 82, thework module 84, the emergency module 86, the communications module 88,and/or the user interface 90.

The display 94 typically comprises an electronic screen which projects agraphical user interface 96 to the programmer. More particularly, thedisplay could be a liquid crystal display (“LCD”), a light-emittingdiode (“LED”) display, an organic LED (“OLED”) display, anelectroluminescent display (“ELD”), a surface-conduction electronemitter display (“SED”), a field-emission display (“FED”), a thin-filmtransistor (“TFT”) LCD, a bistable cholesteric reflective display (i.e.,e-paper), etc. The graphical user interface 94 in response toinstructions received from the operating system 78, the drive module 82,the work module 84, the emergency module 86, the communications module88, and/or the user interface 90.

The means for receiving an input 98 can comprise a combination ofdigital and analog input and/or output devices or any other type of userinterface input/output device required to achieve a desired level ofcontrol and monitoring for a device. Examples of input and/or outputdevices include computer mice, keyboards, touchscreens, knobs, dials,switches, buttons, etc. Input(s) 98 received from the user interface 90can then be sent to the microcontroller 64 to control operationalaspects of the light bar 10.

From the foregoing, it can be seen that the present inventionaccomplishes at least all of the stated objectives.

LIST OF REFERENCE NUMERALS

The following reference numerals and descriptors are not exhaustive, norlimiting, and include reasonable equivalents. If possible, elementsidentified by a reference numeral may replace or supplement any elementidentified by another reference numeral.

-   10 light bar system-   12 housing-   14 circuit board-   16 segments-   18 end caps-   20 encapsulant-   22 control box-   24 microprocessor-   26 memory-   28 clips-   30 truck or vehicle-   32 backwall-   34 sidewalls-   36 cover portion-   38 features-   40 hollow interior-   42 front transparent portion-   44 back non-transparent portion-   46 LEDs-   48 backing material-   50 circuitry layer-   54 seamline-   55 exterior facing surface-   56 wiring-   58 fuse-   60 plug-   62 signal lead-   64 microprocessor-   66 memory-   68 high efficiency step down controller-   70 remote control-   72 non-transitory computer readable medium-   74 central processing unit-   76 memory-   78 operating system-   80 compiler-   82 drive module-   84 work module-   86 emergency module-   88 communications module-   90 user interface-   92 speakers-   94 display, e.g., a touchscreen display-   96 graphical user interface-   98 input-   100 backwall-   102 opposing end walls-   104 opposing side walls-   106 rearward face-   108 rearward face-   110 arms-   112 locking feature-   114 guiding surface-   116 opening-   120 first layer-   122 second layer-   124 TFT LCD-   126 viewing window-   128A first TFT LCD clip-   128B second TFT LCD clip-   130 support bar

The present disclosure is not to be limited to the particularembodiments described herein. The following claims set forth a number ofthe embodiments of the present disclosure with greater particularity.

What is claimed is:
 1. A weather resistant automobile light fixture forinstallation on an external surface of a vehicle, the vehicle having anelectrical system, said weather resistant automobile light fixturecomprising: a circuit board positioned within a housing and operativelyconnected to a thin film transistor liquid-crystal display (TFT LCD); ascreen protector at least partially covering the TFT LCD, said screenprotector formed of a transparent or translucent plastic material; and ahigh-efficiency step-down controller electrically connected to theelectrical system of the vehicle, electrically connected to the TFT LCDand having a microprocessor and a memory; wherein the TFT LCD utilizesoverdrive to send a higher initial voltage than an operating voltage ofthe TFT LCD, moderate said operating voltage and drive rotation ofcrystal molecules in the TFT LCD; wherein the high-efficiency step-downcontroller is configured to operate within the range of negative fortydegrees Celsius to eighty-five degrees Celsius; wherein thehigh-efficiency step-down controller is configured to receive signalsfrom the electrical system of the vehicle, interpret the signalsreceived from the electrical system of the vehicle, and in responseautomatically control illumination of the TFT LCD; and wherein thehigh-efficiency step-down controller automatically activatesindependently controllable portions of the TFT LCD and themicroprocessor is programmed to control colored light emission.
 2. Theautomobile light fixture of claim 1 wherein: the high-efficiencystep-down controller is further configured to select strobing patternsin response to receiving the signals from the electrical system of thevehicle; and the high-efficiency step-down controller is furtherconfigured to select the duration of illumination of the TFT LCD inresponse to receiving the signals from the electrical system of thevehicle.
 3. The automobile light fixture of claim 2 wherein: the one ormore selected strobing patterns are either emergency related orconstruction related.
 4. The automobile light fixture of claim 1 whereinthe housing has wiring electrically connected to the high-efficiencystep-down controller.
 5. The automobile light fixture of claim 4 whereinthe wiring includes a fuse and a signal lead.
 6. The automobile lightfixture of claim 1 wherein: the microprocessor is programmed to controllight emission such that images displayed on the TFT LCD appear as ifobjects are in motion.
 7. The automobile light fixture of claim 1wherein the high-efficiency step-down controller is programmed toautomatically illuminate, via the TFT LCD, red light while a vehicle isbraking, amber light while the vehicle is turning, and white light whilethe vehicle is driven in reverse.
 8. The automobile light fixture ofclaim 1 wherein the TFT LCD has a twisted nematic (TN) display type. 9.The automobile light fixture of claim 1 wherein the TFT LCD has amulti-domain vertical alignment (MVA) display type.
 10. The automobilelight fixture of claim 1 wherein the TFT LCD has a patterned verticalalignment (PVA) display type.
 11. The automobile light fixture of claim1 wherein the housing comprises a back wall, a pair of opposingsidewalls, and a viewing window.